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IMPACT OF EXTRUSION PROCESS ON PRODUCT QUALITY
Sunil Kumar1, P.S Rao2
1ME
Scholar (171222-Modular), Mechanical Engineering, NITTTR CHANDIGARH
2Associate Professor, Mechanical Engineering, NITTTR CHANDIGARH
-------------------------------------------------------------------------***-----------------------------------------------------------------------ABSTRACT - This paper is based on impact analysis of extrusion process on quality of product. Approximately large
number of manufacturers experienced a problem in product quality in established extrusion pipe manufacturing process
to compete the customer demand. To ensure product quality in present extrusion pipe manufacturing process, it is
compulsory to identify, control, and regular monitoring of all quality parameters to ensure product quality. Some of the
important parameters are based on the condition of equipment used in process, operating conditions, temperatures,
pressures, dies quality, and used materials. So many problems faced by the manufacturers to minimize defect in the final
products which directly affect the cost of product as well as product life. The purpose of this paper is to focus to analyze
the various defects in the extrusion process, to access its impact on the product quality and to suggest the mitigation &
remedies for the improvement of extrusion process for better product quality and life.
Keywords: Extrusion process, Defects in plastic pipe, Impact of defect, Product quality
INTRODUCTION
Manufacturing of plastic products in India started 60-62 years ago with the countries. The Indian plastics market is
comprised of around 25,000 companies and employs 3 million people. The domestic capacity for plastic production was
more than 6.72m tonnes in 2016-17. The State of Gujrat in Western India is the leading plastics manufacturing hub and
accounts for the largest number of plastics companies, with above 5,400 plastics firms.
The use of plastic products in other sectors such as automobiles, medical and health care, packaging, sports and leisure is
also increasing. Plastic products is a thermoplastic composed of 57% chlorine and 43% carbon. It is less dependent than
other polymers on crude oil or natural gas, which are non-renewable, and hence plastic products can be regarded as a
natural resource saving plastic.Plastic products can be produced from various hydrocarbons including coal, the bulk of the
world’s plastic products is currently manufactured using ethylene, which is combined with chlorine to produce ethylene
dichloride, the raw material for the manufacture of Vinyl Chloride Monomer. The utilization of plastic products in India is
expected to increase to 3.3 million mt/year by 2017-18 and the nation’s capacity is expected to rise to 1.64 million
mt/year. As is evident from the above-mentioned demand and supply numbers, plastic product demand is expected to
exceed supply.
Extrusion Process
The extrusion changes a solid plastic material into a molten state and then into a final well finished solid plastic product
for use. Equipment of extrusion made of a plastic extruder, die and its assembly, a cooling system, and haul-off or winding
accessories.. Extrusion is a continuous process. Extrusion is used for a uniform outside shape like tubes pipes, railing
window panels etc. The solid plastic material changes into molten metal in the extruder barrel, by shearing of a rotating
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screw and the heat is taken from the heater having electrical resistance which is assembled to the outer side of the
extruder barrel and die. The solid plastic changes into a hot molten material due to shearing action of screw and heating
action of electrical heaters. The screw extrusion and ram extrusion are main two type of plastic extrusion. This review
paper studied about the screw extrusion .In Screw extrusion a helical feed screw rotates into a barrel which is known as
feed screw or the extruder screw which has single shaft with helical flights. For better mixing two screws are used. The
screw pushes the material through the barrel where material is heated and compressed. The extrusion process have two
main purposes: 1 the plastic material is heated above its melting point and puts the melt under pressure. 2The molten
plastic material is pushes and passes through a small hole called as orifice, of die. . The extrusion process is used for pipe,
tubing, window panel, flat products (thin film to heavy sheet), coatings for paper and other substrates, insulation for wire,
cable jacketing, and monofilaments, all synthetic fibers., blown film for bags, cast film for packaging materials, tubing for
catheters, wire insulation for telephone wire, rod for glue guns, profiles for window frames, and monofilaments for fish
line. In the plastic extrusion process plastic is changes into raw material called as pellet or powder, after that powder is
melted and compressed via the extrusion process, passes through the die and changes into final finished desired product.
Defects’ in Extrusion PROCESS
The main defects in plastic extrusion process are due to mould design, wrong material selection, and wrong processing l.
Main defect due to processing are rough surface of product, surging of extruder, variation in thickness, unevenness in wall
thickness, variation in diameter, centering defect. .Processing defects are mainly due to non-understanding of the
processing method, use of inefficient or too old machines, untrained staff, break down of machines, and inappropriate
working environment.
The general defects in extrusion are: wrong selection of System Engineering or its installation, wrong Operation, Defects
in resin, Materials Addition of material, Surging, Poor blending,
fracture or toughness of melt , Overheating, Moisture
release, Trapped air, Contamination.
Wrong selection of System Engineering/Installation
• Wrong used clamp or high tightness of Clamps.
•
die setting is wrong
• Die alignment is not proper
• Improper fire caulk used.
•
Outside pipe contact with incompatible material like solder flux.
Remedies
.Die setting may be adjusted
• Checking of alignment
• Die heating uniformity should be checked
Mall Functioning/operation methods

Freezing temperatures exposure is without freeze protection


Over pressure means pressure is more than normal pressure
Pressure of water is fluctuating
Remedies
•
Digital Pressure gauge should be used
• Proper and Digital temperature sensor should be used
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Defects in Resins
• There is defects of occlusions, char particles, voids
• Distribution of filler/pigment is not proper and well distributed
• Defects in resins due to mixing of resin and additives is not proper
• Defects in resins due foreign contamination
• Defects in resins due to over heating
Remedies
 The resign material screening
 Resin material (Mixing percentage) is not exact
IMPACT ON P[RODUCT QUALITY AND DEFECT
MATERIAL ADDITION NOT PROPER
There are a large no problems due to the processed raw material. There will be problems if raw material is not up to
specification. Regardless of any quality assurances by producer of raw materials and countless programs such as ISO 9000
reengineering, plastic batches and even bags or boxes within batches have their characteristics. The tubing or sheet will
have a different look for different extrusion parameters, bend, colour, or shape. These problems do occur on the floor
during processing. In spite of all the computer programs and hardware designed to maintain the quality constant, there
will be so many variations arise. Many plastic materials such as polyurethane, nylon and others, are hygroscopic (they
absorb moisture from the air).the presence of moisture content in product is undesirable and can create bubbles in the
melt can decrease barrier properties. To prevent form such type of problems the polymer should be proper sealed in bags
nitrogen-purged whenever possible. Though, some plastics can absorb critical amounts of moisture in the time it takes to
open a bag and put it in the hopper. The material must be dry out properly, preferably in a hopper dryer designed for this
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purpose. Other problems include contamination with foreign materials such as metal chips, screws, bolts, nuts and rodent
droppings. Even medical grade plastics are often contaminated. Of course, the contaminate will end up in the melt, so
every precaution must be taken to avoid contamination by closing bags, covering hoppers, keeping a clean area around the
extruders, and similar measures.
Remedies
• Addition of (mixing percentage) resin material should be exact
• Foreign material should be checked
•
RPM back pressure should be increased for better mixing.
SURGING
Surging is a cyclical product thickness variation in the direction of extrusion. The surge cycle time is typically between 30
seconds and 3 minutes, and the cause can be inside or outside the extruder. Outside causes are easier to see and correct.
For example, the take-off pull may be irregular; in this case the screw rpm and ammeter readings remain steady.
Sometimes screw motor speed varies because its regulation is not working properly. This is rare and will show up as
unsteady rpm. Sometimes the feed is uneven because of particle size, light weight, or bridging in the hopper and throat.
With very small extruders, the feed channel depth is not much bigger. Than the feed particles, and they may feed
erratically for this reason alone.
If none of these outside causes are observed, it is probable that the surging originates inside, typically at the beginning of
the compression zone, where the solid bed the mass of pellets may be locking and breaking up irregularly. Screw rpm is
steady but the ammeter shows variations of ± 5% or more. Sometimes this can be cured by increasing the temperature of
the feed to promote earlier melting. Raising the rear barrel temperature may help, too. Make big changes, 25-50 °F (14-28
°C), and see what happens. Sometimes raising the barrel Temperature at the beginning of the compression zone will help
by getting better sticking of the pellets to the wall there.
Remedies
• Try to running the extruder slower or faster by at least 10%.
• Altering or replacing the screw.
• Installing a gear pump between the extruder and the die.
POOR MIXING
This often sets the upper limit for output. The screw cannot be run any faster because the material is coming out with an
“applesauce” surface, with streaks, parabolic ridges, and perhaps Particles of undispersed additive. Screw modifications,
such as pins or separate mixing heads will help, but may raise melt temperature. Running more slowly will always help, as
it provides more residence time. A screw with internal cooling mixes better because it has the effect of a shallower channel
in the metering zone. The output per rpm drops 30, but may be regained by increasing the screw speed, unless melt
temperature gets too high or the drive system cannot safely run faster. High pressure is good for mixing. A valve will do
this, or a gear pump pressure control that can serve as a valve. Cooler dies increase the resistance and thus raise the
pressure in the system. Finer screens will raise the pressure, but as they keep clogging, pressure is inconsistent.
Remedies
• Exact addition of (Percentage of mixing) resin material.
• Check for foreign material.
• Increase rpm back pressure for better mixing.
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MELT TOUGHNESS OR MELT FRACTURE
This refers to fine ridges or rough surface seen when the melt comes too fast out of a narrow die. It is most common with
polyethylene, and can be eliminated by running the melt or the die lips hotter, using a longer or more streamlined die, or
trying a different grade or source of material. Additives may help greatly in this regard.
Remedies
• Use the Correct additives.
• Maintain the speed of extruder.
• Trying a different grade or source of material.
OVERHEATING
Overheating may limit the rate if the take-off cooling is limited, or it may produce degradation or make dimensional
control and sizing difficult. In such a case, stop all barrel heat except in the rear zone as needed for bite (input) control and
cool the barrel if necessary. (In a few cases, more barrel heat will yield a cooler melt.) There is a temperature below which
the melt will not go at a given screw speed, even if all the barrel heaters are turned off.
See if the controller around 70% down the barrel is overriding. This means over packing of the metering zone—
overbite—with much heat generated at the entry to that zone. In that case, reduce the bite by changing the feed
temperature, rear barrel temperature, or particle size.
Remedies
• Stop all barrel heat except in the rear zone as needed for bite (input) control and cool the barrel if necessary.
MOISTURE RELEASE
Moisture is absorbed by some plastics. It passes through the extruder and boils when the pressure is relieved at the die
lips. The result is a pattern of dotted lines, long bubbles, and pits. To remove moisture, the material must be pre-dry, or a
vent must be used in the extruder, or both. A moisture level of 0.1% is usually low enough to avoid such visual problems.
Some plastics, such as PET, the nylons, and polycarbonate, can degrade and weaken if even a tiny amount of moisture is
present when they are melted. For these, dehumidifying dryers are used to get moisture down to 0.01% or less.
Remedies
• To remove moisture, the material must be pre-dry.
• Vent must be used in the extruder.
• Keep the moisture level of 0.1% is usually.
TRAPPED AIR
This is not common in pelletized material used with long extruder barrels. However, some old machines have short
barrels, and even a long machine can be pushed so fast that the air is carried forward into the product. A trapped-air
surface shows bubbles and pits, but little, if any, dotted lines. Such a surface will improve if run more slowly if moisture is
not the problem. A cooler head and die may help. Vents and vacuum hoppers will eliminate trapped air and are essential
for powders, where passages between the particles are much smaller; the air cannot escape back through these passages
and is carried forward instead.
Remedies
• Avoid the over-speed of extrusion.
• Pre-Dry the material.
• Vents and vacuum hoppers will eliminate trapped air.
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LITERATURE REVIEW
S.No
Author
Process Review
Output parameter
Benefits/Conclusion
1 J G Khan, R S
Dalu and S S
Gadekar
Defects In
Different defects in the plastic
Extrusion
extrusion process, to recognise its
Process And impact on the product quality and to
Their Impact On
suggest for improvement of
Product Quality extrusion process for better quality.
From analysis of the different papers related to defect and
observing their views of many researchers on plastic extrusion
process there should be need of reduce the causes for the best
possible extrusion product output. These quality Causes are
become inappropriate setting of operational parameters as per
observation. By the application of above remedies the percentage of
loss would be improve, as predicted, for the products.
2
Recent Methods Process parameters and die design
For ptimization for plastic extrusion. Analysis based
Of Plastic
on various approaches:
ExtrusionProces

Taguchi technique
s: A Literature

artificial neural networks
Review
(ANN), fuzzy logic
Different research works on the basis of different approaches :
Geo Raju1,
Mohan Lal
Sharma2,
Makkhan
Lal Meena3

genetic algorithms (GA)

non-linear modelling

3
WA
Development Of
Akinfiresoye A Wood Plastic
*, OJ
Composite
Olukunle
Extruder
and AA
Akintade
response surface
methodology
comparison of extrusion and
injection moulding for producing
WPC are as:

melting

shaping
Dharmendr
Process
a Kumar (M. Parameters
Tech
Optimization For
Scholar), HDPE Material In
Sunil Kumar Extrusion Blown
(Asst.
Film Machinery
Professor) Using Taguchi
Method
5
Mitul J.
Review Finite Change the design of the sheet that
Barot, Tejas Element Analysis have more strength by using FEA
B. Mehta,
And
method and optimize the window
C.E.Vijay Optimization Of
sheet by using taghchi method,
Parekh
PVC
therefore to understand the plastic
Window Profile extrusion process, to understand its
process parameter researcher study
various research paper related to
extrusion process. And present the
brief review of thus paper.
|
c.
d.
artificial neural networks (ANN),
fuzzy logic, genetic algorithms (GA),
e.
non-linear modelling
Taguchi method is a robust design technique used in industries for
making the product/process may insensitive to any uncontrollable
factors such as environmental variables. Taguchi approach has
helped in reducing the experimental time and cost of product and
quality improvement for better quality. In similar way ANN and GA
are used to examine as the new approaches to analyse of different
process parameters to get best product quality.
small scale wood-plastic composite extruder machine was
designed, fabricated and tested at the Agricultural and
Environmental Engineering department of The Federal University
of Technology,Akure. The extruder is powered by 10Hp three phase
electric motor.

and cooling
Extrusion and injection moulding
both are use screws to convey, pump,
and blend the mixed component but
pressure and shearing in injection
moulding are higher than extrusion
regardless the process parameters
mentioned.
4
© 2019, IRJET
a. mathematical model,
b. Taguchi technique,
The optimum level of the process
Combination parameter is find out by selecting level with highest
parameters is greatest S/N ratio.(I
value for each factor. The optimal process parameter is the
)melting (ii) temperature
combination for HDPE is A3, B3, C3, D2.The value difference given
(iii)extrusion speed(iv) extrusion
table shows which one factor is the most important Tensile
pressure (v) winding speed
strength for HDPE, Melting Temperature (B) is determined by most
considered. Orthogonal array
effective factor for HDPE which is follow by Extrusion speed (D)
experiments were conducted. After
Extrusion pressure (A) and Winding speed (C).
conducting the experiments, the
tensile strength is measured and
Signal to Noise ratio is calculated.
graph and table helps to find out
optimum parameter values
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A finite element analysis of extrude product is very useful to study
the effects of various parameters like Melting temperature, Screw
speed, Extrusion pressure, Extrusion ratio, Die angle which are
difficult to measure during process and all these parameters have
significant effects on microstructure, extrude quality, material flow
behaviour and strength of the extrude. So these parameters need to
be analysed and according to this modelled the extrude product.
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S. Ravi, M.
Design Of
GA ANFIS contro-paperller design
GA ANFIS Controller have capability to eliminate sudden input
Sudha, and Intelligent Self- method for temperature control in disturbance and maintain the set point temperature in the plastic
P. A.
Tuning GA ANFIS
plastic extrusion system.
extrusion system. The simulation results clearly show that the GA
Balakrishna Temperature
Temperature control of plastic
ANFIS controller reduces the timing specifications of fuzzy and PID
n
Controller For extrusion system suffers problems controllers. This paper demonstrates the effectiveness of intelligent
controller on nonlinear system, particularly for temperature
Plastic Extrusion related to longer settling time, couple
effects,
large
time
constants,
and
control in plastic extrusion system.
System
undesirable overshoot.
The system is generally nonlinear
and the temperature forth plastic
extrusion system may vary over a
wide range of disturbances.
7
8
M.
Performance
hirumarimu Evaluation Of
rugan, S.
Extrusion
SivaSubram
Process
anian and
M.Ramasubr
amanian
Alternative technique is used to
control the temperature in the
extrusion process. It is used for
better performance than the
conventional controllers
Prabhat
Temperature
Four control techniques PI, PID
Kumar
Control For
FUZZY and ANFIS. The tuning
Mahto , Plastic Extrusion synchronizes monitor the controlled
Rajendra
variable and process to work at its
Process
Murmu
desired operating condition. All
method is simulated using
MATLAB/Simulink.
This work provide extrusion process temperature controllers
which is used to understand the actual thermal behaviour for the
melt flow for evaluating controller performance. Many techniques
have been used in extrusion process. Experimental study shows
various controllers have some performance drawback which can be
overcome by the addition of anti-windup compensators which
reduces the overshoots caused by the integral part of the controller
section. An anti-windup compensator is made of nominal controller
appended with anti-windup compensation. The reason behind
using anti-windup compensation is that it leaves the loop
unaffected as long as saturation does not occur. To prevent the
integrator state is prevented from growing large and cause over
shoots and limit cycles we have opted for anti-windup
compensation. Hence the usage of anti-windup compensator will
improve the performance of the controller system
It concluded the design, analysis and suitability for extrusion
temperature response control model for plastic extrusion by ANFIS
control, FLC, PID and PI control. A comparative study of
performance of PI, PID, fuzzy logic controller and ANFIS controller
is studied. It uses MATLAB/Simulink for simulation. Due to sudden
input disturbances and different set points temperature changes
for plastic extrusion system.
9
A. Hosseini, Effect Of Process Hot and cold crack defects generated
1) By friction stir extrusion processing method defect free
E.Azarsa, Parameters On on wires made due to too high and aluminium wires can be fabricated from aluminium chips that had
B.Davoodi,
The Physical
low die rotational speed,
been produced through other manufacturing processes. 2) Limits
Y.Ardahani Properties Of
respectively. Defects, voids in the
on the process appear to be related to the extrusion temperature
Wires Produced wires will increases with increase in which, if too low, results in cold tearing and, if too high, causes what
die transverse speed.
appears to be a form of hot cracking. 3) From macroscopic and
By Friction
microscopic evaluations it can be inferred that the optimum
Extrusion
condition for
Method
10
Ismail
A Temperature
In fuzzy logic, it represents the
GA has been successfully applied to solve many optimization
Yusuf, Nur
Control For
degree of as an extension of
problems. In this research, genetic algorithms are implemented to a
Iksan ,
Plastic Extruder valuation. Conventional FLC used system (programming language) for determining the membership
Nanna
membership function generated by function of FLC. By designing compact data structures for genes and
Used Fuzzy
Suryana
human operators, who have been chromosomes and an accurate fitness evaluation function, GA have
Genetic
Herman
manually
designing the membership been implemented which is very effective in finding more accurate
Algorithms
function of FLC. To satisfy such
membership functions for the fuzzy system. The data structures
requirements include one common adopted are compact, and thus very convenient to manipulate by
weakness where the membership genetic operators. The performance of GA can be further improved
function selection process is done by using different combinations of selection strategies, crossover
with trial and error; it runs step by
and mutation methods, and other genetic parameters such as
step, which is too long in completing
population size, probability of crossover and mutation rate.
the problem. A new approach for
optimum coding of fuzzy controllers
using GA. GA is used to determine
membership function especially
designed in situations.
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11 S. RAVI, P.A.
Stable SelfIn order to produce a good quality of This paper demonstrated the design, analysis and suitability of
BALAKRISH Tuning Genetic plastic extrudates the temperature in
temperature response control model for plastic extrusion by
NAN
Fuzzy Logic
each zone must be set appropriately
Genetic Algorithm tuned FLC control. Due to sudden input
Temperature
and precisely controlled. In this
disturbances and different set points temperature changes for
Controller For
paper GA based FLC control
plastic extrusion system, the simulation results show the FLC
Plastic Extrusion technology in temperature response
control is with little overshoot and take a delay to settle with
System
control for the plastic extrusion reference value. Genetic Algorithm controller FLC tuning is without
system at different set point changes overshoot and settle very quickly compared with FLC controller.
and sudden disturbances compared This paper demonstrates the effectiveness of intelligent controller
with fuzzy logic control. Details of on non-linear system particularly for temperature control in plastic
plant model, control methods, design extrusion system. The proposed controller identifies the process
and simulation results are
variations quickly and provides good control for the set point
Presented in the subsequent
sections.
12
Ismail
A Temperature
Yusuf, Nur
Control For
Ihsan ,
Plastic Extruder
Nanna
Used Fuzzy
Suryana
Genetic
Herman
Algorithms
changes and for sudden disturbances. The Genetic Algorithm based
FLC controller will prove especially efficacious in plastic extrusion
system.
Determine the membership function
GA has been successfully applied to solve many optimization
of FLC using the GA optimization for problems. In this research, genetic algorithms are implemented to a
the fastest processing in completing system (programming language) for determining the membership
the problems. The data collection is function of FLC. By designing compact data structures for genes and
based on the simulation
chromosomes and an accurate fitness evaluation function, GA have
results and the results refer to the been implemented which is very effective in finding more accurate
membership functions for the fuzzy system. The data structures
maximum overshoot. From the
adopted are compact, and thus very convenient to manipulate by
results presented, we will get a
genetic operators.
better and exact result; the value of
overshot is decreasing from 1.2800
for FLC without GA, to 1.0011 for
FGA.
13 Dharmendr
Process
a Kumar (M. Parameters
Tech
Optimization For
Scholar), HDPE Material In
Sunil Kumar Extrusion Blown
(Asst.
Film Machinery
Professor) Using Taguchi
Method
14
Four factors namely
melting temperature

extrusion speed

extrusion pressure

and winding speed
The best group of combination parameter in the tabular form can
be examined by choosing the level with highest value for given
factor. The difference value from said analysis represent which one
factor is the most important for Tensile strength of Melting and
HDPE. Temperature is found most effective factor for HDPE
followed by Extrusion speed (S) Extrusion pressure (P) and
Winding speed (Vw).
S.Siva
A Review On
Investigate about the application of
Genetic Algorithm has been used to solve many optimization
Subramania Control Of Plastic genetic algorithm in the design and problems. In this paper genetic-algorithms are applied to a system
n1, S.Durga,
Extrusion
implementation of Fuzzy logic
for defining the membership functions. This method developed a
K.R.Loshni,
controller.
FL
Controller
use
system that helps users to defining the membership function of
Process
V. Dinesh
membership function generated by Fuzzy Logic Controller using the Genetic Algorithm optimization
Kumar
human operators.
method for the fastest processing in completing the problems. The
data collection is based on the simulation results and the results
refer to the maximum overshoot. Plastic extrusion verified to be a
robust method and it is valuable in all type of industries expanding
the scope to include a range of polymers that can be processed with
or without plasticizers.
CONCLUSION
From the different studies and analysis of the various papers related to defect and observation of different researchers by
papers related to extrusion process need to minimize its defects for the best extrusion product quality. Such quality
problems are become inappropriate setting of operational parameters as per observation taken by the researchers. By the
use of above methods to minimize the percentage of loss would be improve, as predicted, for the products.
REFERENCES
[1] J G Khan RS Dalu and SS Gadekar, “Defects in Extrusion Process and Their Impact on Product quality”,
International Journal of Mechanical Engineering and Robotics Research July 2014, Vol.3 ISBN: 12278-0149.
[2] Geo Raju, Mohan Lal Sharma and Makkan Lal Meena, “Recent Methods for Optimization of Plastic Extrusion
Process:aliterature Review” International Journal of Advanced Mechanical Engineering ,2014 ,ISSN 2250 -3234
,VOL4 , Number 6
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[3] WA Akinfirresoye , OJ Olukunle and AA Akintade , “International Journal of Waste Resources, 2017, ISSN:22525211.
[4] Dharmendra Kumar and Sunil Kumar, “Process parameters optimization for HDPE material in Extrusion Blown
Film Machinery using Taguchi method” Review IOSR Journal of Mechanical and Civil Engineering (IOSR –JMCE),
July-august 2015, Vol 12, ISSN: 2278 -1684, p – ISSN :2320-334X
[5] Mitul J Barot ,Tejas B. Mehta and CE, Vijay Parkeh “Review on Finite Element Analysis and Optimization of PVC
Window Profile”, January 2015,Volume2,ISSN 2394 -3386
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